GE

Plastics

Valox*
PBT/PET/PC resin
performance featured product guide
Valox PBT/PET/PC Resin
Developed in 1970 by GE Plastics, Valox* resin has become a very
popular brand of PBT. With manufacturing and compounding facilities
around the globe, GE Plastics has continued to introduce new
products and blends with enhanced performance.

Manufacturing Locations

Whether youre a small business that designs, engineers and manufactures in one location or a multinational
corporation that develops in one pole and manufactures in another, GE Plastics is ready to support your success.
Content

1. Introduction 4 8. Weatherable Valox resin 16

2. General purpose Valox resin 6 9. FDA (food contact) and

healthcare Valox resin 17

3. Impact modified Valox resin 7

10. Specialty Valox resin 18

4. Hydrostable Valox resin 8

11. Laser marking on Valox resin 19

5. Electrical Valox resin 10

12. Valox resin product tree 22

6. Aesthetics
6.1 Color stable Valox resin 11 13. Valox resin product information 24

6.2 Heavy Valox resin for aesthetic applications 12

6.3 Visualfx Valox resin 14 14. Mold design 30

7. Metalizable Valox resin 15 15. Equipment 33

16. Molding conditions 35

3 GE Plastics Valox PBT/PET/PC resin

1. Introduction Valox PBT/PET/PC Resin

Valox resin can help make customer applications safe and reliable.
Long-term heat resistance Dimensional stability
Dielectric properties Creep resistant
Chemical resistant Impact resistant
Stiffness and strength

With value added features to meet extreme weather conditions,

stringent safety regulations and complex part design.

Valox PBT/PET/PC resin GE Plastics 4

Valox Polyester Resin
This family of resin includes PBT (polybutylene
terephthalate), PET (polyethylene terephthalate) and
polyesters blended with polycarbonate.
These resin can be modified to offer exceptional
performance in a wide variety of demanding
applications.
Also included are a large number of general purpose
and specialty grades for specialty performance
applications.
All the grades are designed to offer an excellent
balance of physical, electrical, chemical and aesthetic
properties to meet a wide range of applications.
Valox PBT/PET polyester resin and blends with
polycarbonate resin offer processing flexibility,
enhanced quality and productivity. The product line
includes grades for injection molding, extrusion, blow
molding and structural foam. It also includes a full line
of flame retardant grades to meet UL regulations.
Typical property profiles of Valox resin include high
dielectric strength, high heat resistance, excellent
resistance to many common chemicals and good
barrier resistance.

Processing characteristics include excellent flow, fast

Table 1: Valox
PBT/PET/PC resin cycle times and excellent blow molding performance
performance General Purpose with designated grades.
products

Impact Modied Aesthetic options include high gloss capability and

incorporation of visual effects.

Hydrostable
The Valox resin portfolio is constantly modified to meet
demanding applications in industries such as:
Electricals Electrical and lighting
Automotive
Valox Telecommunication
PBT/PET/PC Aesthetics
resin Medical
Food
Metalizable Appliances
Business machines
Weatherable Textiles

FDA/Medical

Specialty

5 GE Plastics Valox PBT/PET/PC resin

2. General purpose Valox resin
General purpose grades of Valox resin include a wide variety
of standard and flame retardant versions in both unfilled and
glass filled grades.
Potential application benefits: Product compliance:
Excellent balance of properties Long history
Enhanced flow Strong agency approval
Impact modified Global availability/local fulfillment
Largest portfolio
Potential processing benefits: Valox 420SEO resin a global benchmark
Wide and robust processing window Flame retardant grades meet UL, CSA, IEC
Fast cycle times and EN standards
Lower drying temperatures Potential applications:
Maintains performance with recycle Automotive underhood (connectors, sensors)
Industrial sensor and connector applications
Applications where heat and humidity
are a challenge

Table 2
Typical general purpose Valox resin grades
325 Unfilled non-FR general purpose
grade
310SEO Unfilled FR general purpose grade,
passes UL 94 V0 at 0.70 mm
4022 20% glass filled non-FR general
purpose grade
420 30% glass filled non-FR general
purpose grade
457 7% glass filled FR general purpose
grade, passes UL 94 V0 at 0.70 mm
451E 20% glass filled FR general purpose
grade, passes UL 94 V0 at 0.70 mm
420SEO 30% glass filled FR general purpose
grade, passes UL 94 V0 at 0.70 mm

Valox PBT/PET/PC resin GE Plastics 6

3. Impact modified Valox resin
GE Plastics is an industry leader in material blend technology. Our
Valox resin product line takes advantage of this expertise to provide
unique combinations of chemical resistance coupled with improved
impact performance. High impact is a differentiator offering higher
value application.
Potential application benefits: Potential applications:
Low temperature impact to -40C Sports and leisure snowmobile parts
Most unfilled flame retardant IT cabinets
Impact resistance coupled with weatherability Connectors
MCB, MCCB
Potential processing benefits: Industrial plugs and sockets
Excellent flow/thinwall
Table 3
Typical impact modified Valox resin grades
Product compliance:
337 Unfilled non-FR impact modified
Flame retardant grades meet UL, CSA, IEC grade with an excellent impact
and EN standards resistance at low temperature
357, 357M, Unfilled impact modified FR grade,
357X, 357XM, passes V0 at 0.70 mm. Available with
357P, 357XP easy flow and mold release
365 Unfilled FR impact modified with
good chemical resistance and
dimensionally stable grade
PDR4926 18% glass filled PBT grade, impact
modified FR, passes UL 94 V0 at 0.75
mm
VIC4311 30% glass filled, excellent impact
modified
VIC4320N 30% glass filled, impact modified
VIC4350 33% glass filled PBT FR, passes UL
94 V0
VX3608C Unfilled PBT/PC impact modified
blend with FR, UL 94 V0 at 1.6 mm

7 GE Plastics Valox PBT/PET/PC resin

4. Hydrostable Valox resin
Valox resin hydrostable grades provide enhanced retention of
physical properties when exposed to extreme heat and humidity.
They provide unparalleled performance in hot/humid environments.
Potential application benefits:
Improved property retention in heat/humidity
High flow to fill complex molds
Impact modified for enhanced toughness
Potential processing benefits:
High flow to fill complex molds
Fast cycling
Lower drying temperatures
Maintains performance with recycle
Product compliance:
Passes USCAR up to Class IV protocol
Potential applications:
Automotive underhood (connectors, sensors)
Industrial sensor and connector applications
Applications where heat and humidity are a
challenge
Buffer tubes for fiber optics
Specialty fibers
Valox PBT/PET/PC resin GE Plastics 8
Table 4
Typical hydrostable Valox resin grades
HR326 Unfilled high viscosity PBT with
enhanced hydrostability and
improved chemical resistance
HR326HV Unfilled high viscosity PBT (higher
than HR326) with enhanced
hydrostability and improved
chemical resistance
HR426 30% glass filled PBT with enhanced
hydrostability and excellent
mechanical properties
K3501 Unfilled heat stabilized PBT with
mold release, impact modified and
improved hydrostability
K4530 15% glass filled PBT grade with
enhanced hydrostability and flow
K4560 30% glass filled PBT grade,
impact modified with enhanced
hydrostability and flow
V3100HR Unfilled high viscosity PBT grade with
enhanced hydrostability
V4860HR 30% glass filled FR PBT grade with
enhanced hydrostability and impact,
passes UL 94 at 0.80 mm
VX4015 15% glass filled PBT injection
molding PBT grade with enhanced
hydrostability
 USCAR (United States Council for 5 year bumper-to-bumper warranty
Automotive Research), a Consortium
Automotive 10 year bumper-to-bumper warranty
Manufacturers
of Domestic (US) Automotive Requires data under accelerated
Manufacturers, is the umbrella conditions
organization of DaimlerChrysler,
Ford and General Motors, which was Part Molders Standard Tests developed by USCAR
formed in 1992 to further strengthen USCAR Class II, III, IV Part tests under
the technology base of the domestic accelerated conditions
auto industry through cooperative
research.
Resin Suppliers ASTM, ISO-tests after heat/humidity
aging Use the same protocol as USCAR
Class II, III, IV Internal Test methods
e.g., Autoclave

Dry Heat Aging Actual end use parts are tested as per USCAR Class categories for 6 weeks
Humidity/Heat Cycle Part Test
1 cycle = 8 hrs.
Parts must pass 40 cycles

Categories
Standardization of terminal systems
Category 0 0.64 mm Terminal System
Temp (C)

Category 1 1.0 mm Terminal System

Category 2 1.5 mm Terminal System
Category 3 2.8 mm Terminal System
Category 4 6.4 mm Terminal System

Time (hr)

Classes
Environmental performance requirements
Class 1 85C Ambient Temp.
Humidity (%)

Class 2 105C Ambient Temp.

Uncontrolled
Class 3 125C Ambient Temp.
Class 4 155C Ambient Temp.
Heat Aging for 1008 hours
Heat and Humidity Cycling for 40 cycles
Full Listing of Chemical Exposures
Time (hr)

9 GE Plastics Valox PBT/PET/PC resin

5. Electrical Valox resin
The Valox resin portfolio has grades for electrical industries that
meet high RTI and GWIT application standards. They offer heat
and color stability, provide adhesion to epoxy, allow laser marking
on custom colors and are flame retardant.
Potential application benefits:
Better hydrostability vs. PA
Electrical performance high CTI/GWIT
High heat, color stability
Thinwall design with dimensional stability
Potential processing benefits:
Cycle time
Excellent flow with minimum warpage
Laser marking
Product compliance:
UL listing 1446
UL 94 V0 FR
Valox PBT/PET/PC resin GE Plastics 10
Potential applications:
Coil bobbins
E-motors
High CTI/GWIT applications
Circuit breaker housings
Lamp holders
Terminal blocks for energy meters
Indoor electrical enclosure
Table 5
Typical electrical Valox resin grades
467 30% glass filled PBT/PC blend FR
grade, impact modified
771 30% glass/mineral filled FR grade,
passes UL 94 VO at 0.75 mm and CTI
Class 0, 600 Volts
4521, 4521B 20% glass filled FR grade with
enhanced flow, passes UL VO-0.75
mm and CTI Class 2
553 30% glass filled PBT/PC blend with an
excellent dimensional stability and
FR, passes UL 94 VO-0.86 mm
732E 30% glass/mineral filled with
excellent thermal stability, low
warpage and enhanced flow
735 40% glass/mineral filled PBT/PET
blend, impact modified
745 29% mineral filled PBT/PC blend with
an excellent dimensional stability and
impact
V8560 30% glass filled FR PBT/PET blend
with enhanced heat stability and
mold release
V9561 30% glass filled PET FR grade, passes
UL 94 at VO-0.80 mm
VX3603C Unfilled PBT FR grade, passes UL 94
at 0.75 mm and CTI 275 V
6. Aesthetics
6.1 Color stable Valox resin
Valox resin aesthetics grades can improve the value of your product
without compromising its functional requirements. These grades provide
a more appealing look and product differentiation at the marketplace.
Color stable Valox resin
Potential application benefits:
High gloss with color stability
Good mechanical and chemical properties
Increased strength, stiffness and heat
resistance vs. unreinforced grades
Excellent surface finish
Potential processing benefits:
High flow, faster cycle times
Robust processing window
System cost reduction by eliminating
secondary operations like painting
Product compliance:
UL 94 V-0 grades
Potential applications:
Household appliance components
Consumer products
Hot air gun assemblies, industrial guns
Table 6.1
Typical aesthetics Valox resin grades color stable
815 15% glass filled PBT/PET blend with
improved surface appearance
815F 15% glass filled PBT/PET blend with
improved surface appearance
830 30% glass filled PBT/PET blend with
improved surface appearance
830EI, 830M, 30% glass filled PBT/PET blend with
830R, 830X improved surface appearance and
enhanced flow, impact modified, mold
release or low cost
855 15% glass filled PBT/PET blend with
improved surface appearance and FR,
passes UL 94 VO at 1.50 mm
865 30% glass filled PBT/PET blend with
improved surface appearance and FR,
passes UL 94 VO at 1.70 mm
CS8115, 15% glass filled PBT/PET blend with
CS8115U improved surface appearance and
enhanced heat aging color stability and
weatherability
CS815 15% glass filled PBT/PET blend with high
surface gloss and improved heat aging
color stability
CS860 30% glass filled PBT/PET blend with
good surface appearance, passes UL
94 VO at .750 mm and improved heat
aging color stability
V4280 15% glass filled PBT/PET blend with
enhanced surface appearance and high
modulus
V9260CS 30% glass filled PET grade with
enhanced color stability
V9540CS 20% glass filled FR high heat PET grade
with enhanced color stability
VX8016 15% glass/mineral filled PBT/PET blend
with enhanced surface appearance
VX8532 30% glass filled non-blooming FR
PBT/PET grade with enhanced surface
appearance and ultrasonic weldability
11 GE Plastics Valox PBT/PET/PC resin
6. Aesthetics
6.2 Heavy Valox resin for aesthetic applications
A unique, high density PBT material that combines the inherent
characteristics of PBT with the advantages of high levels of mineral
reinforcement.
Heavy Valox resin is a highly filled PBT resin, based
on a unique property combination of:
High thermal performance (up to 250)
Chemical resistance (many domestic cleaners
and urea)
Dimensional stability
High density (1.85 gr/ cm3)
FDA and BGA approval
Quality feel and high quality surface
Incoloring and visual effect capability
Surface renewal ability
This unique combination of properties offers
new added value for applications which require
aesthetics.
Heavy Valox resin provides the following added
value features:
Aesthetics (color, visual effects like metallic and
granite looks)
Quality feel (stone-like feel and weight)
Performance (thermal, hot/cold shock performance)
Renewal ability (surface can be softly sanded
to renew)
Plating performance (metal look and feel)
Valox PBT/PET/PC resin GE Plastics 12
Heavy Valox resin is an excellent candidate in these
segments:
Bathroom equipment and appliances (shower trays,
sinks, urinals, soap trays, toothbrush bodies, toilet
seats, etc.)
Housings for electronic/electric equipment requiring
aesthetics (speaker boxes, remote controls, knobs/
switches for stereo equipment, housings, handles for
kitchen appliances)
The fashion industry (buttons, beads for trendy
jewelry, etc.)
Heavy Valox resin can provide added value and
system cost advantages versus competitive
materials, such as:
Thermosets
Ceramics
Stainless steel or enameled steel
The downside of these competitive materials is their
flexibility in shape, integration, visual effect, cycle time
and tooling cost (ceramics), and recycle problems.
Recent commercial examples:
Trendy sources for coffee cups
Waterless urinal with metallic sparkle effect for a
granite look
Speaker box housings
Reasons for choosing heavy Valox resin are: aesthetic Table 6.2
look and feel like ceramic or stone, chemical resistance Typical aesthetics Valox resin grades heavy Valox
(Enduran*) resin
against domestic cleaners and urea, flexibility in color
7062 38% mineral filled PBT/PET blend with
and effects, and flexibility in design freedom. Ideal high dimensional stability and excellent
choice for bathroom applications like the urinal where surface appearance
staining can occur. The unique property of renewability 7065 63% mineral filled, PBT/PET blend with
is a key differentiator. This means that if a stain does high dimensional stability and excellent
surface appearance
occur on the surface it can easily be polished away
7085 67% glass/mineral filled PBT/PET blend
by means of a standard commercial (green/yellow) with good surface finish
washing pad. 7322 37% mineral filled PBT/PET/PC blend
with improved surface appearance and
UV stability
The heavy Valox resin key commercial grades
7062HP 38% mineral filled PBT/PET blend with
available:
excellent dimensional stability and
7062 surface appearance
7062X 30% glass filled 7062X 45% glass/mineral filled PBT with
Color: most colors (non-bright) are possible excellent dimensional stability and
surface appearance
Visual effects like Stone, Metallic and
Glow in the Dark are possible
Color and visual effects should be discussed
with the product manager

Table 6.3 Typical heavy Valox resin product data

7062 7062X
Density (gr/cm3) ISO 1183 1.85 1.85
Tensile strength (Mpa) ISO 527 60 105
Tensile Modulus (Mpa) ISO 527 4500 8200
Izod Impact (un KJ/m2) ISO 180/1U 27 33
MVR (265C/1.2kg) 30 20
Vicat (B/120C ) ISO 306 187 218
Scratch resistance DIN 53799 Moderate/Fair
Abrasion resistance Taber 110 mg
Hot pan test DIN 53799, part 4.9 250C
Cigarette burn test ISO 4586-2, part 18 No destruction to surface (Class 2)
Hot cold test shock ANSI 2124.2, part 6.3.2 Pass 1000 cycles, no visual damage
Chemical resistance ANSI Z124.6 Pass all chemicals, repairable cigarette stain

Table 6.4 Heavy Valox resin performance versus competition

Material Scratch Abrasion Heat Impact Water Chemical Processability Quality
Resistance Resistance Resistance Resistance Resistance Resistance Appearance
SMC thermoset coated ++ 0 + 0 + + +
Polypropylene filled -- ++ ++ ++ ++ 0
Lexan* 0 ++ 0 ++ +
PMMA filled minerals 0 0 + 0 ++
Heavy Valox 7062X 0 + + + + + + ++

Scale: poor moderate 0 fair + good ++ excellent

13 GE Plastics Valox PBT/PET/PC resin

6. Aesthetics
6.3 Visualfx* Valox resin
GE can design and supply tailor-made Visualfx Valox resin from our
wide range of patented technology to help meet your complex part
geometry for a flow line, free end product. We can also assist you with
our technical experience.
New Ideas Concept Design Visualfx Valox resin Table 6.5
Win in the marketplace Value proposition Typical aesthetics Valox resin grades
Visualfx Valox resin
FXV310SK Unfilled PBT injection molding grade
Application benefits: with Visualfx pigment for automotive
Product differentiation bezel applications or front grilles
Quality feel/quality look
Cost out no secondary operations
Mechanical performance

Applications:
Automotive bezels
Automotive front grille
Household
Bathroom accessories, urinal pot and lid
Cosmetics jars and lids
Door handles, mirrors, roof racks

Valox PBT/PET/PC resin GE Plastics 14

7. Metalizable Valox resin
Metalizable Valox resin grades provide exceptional results for use in
base coated headlight bezels or direct metalization applications.

Potential application benefits: Potential applications:

Thinwall/low part weight due to high flow Headlight bezels
Excellent dimensional stability Tail-light reflectors requiring high heat performance
Visualfx resin options available High mount stop light reflectors
DLV3000 indoor down light reflectors
Potential processing benefits:
Low cycle times
Reduced injection pressures Table 7
Anti-static to maintain dust-free surface (EH7020HF) Typical metalization Valox resin grades
DLV3000 Metalizable PBT with higher heat
resistance
Product compliance:
DLV3100 Metalizable antistatic PBT with higher
Global production capability heat resistance
In-house evaluation at processing centers EH7020HF 20% talc filled metalizable PBT
with enhanced flow for automotive
applications

15 GE Plastics Valox PBT/PET/PC resin

8. Weatherable Valox resin
The Valox resin weatherable products retain their physical properties
and flammability performance while they meet extreme outdoor
weather conditions. They are also available in custom colors for product
differentiation in the marketplace.
Potential application benefits: Table 8
UL F1 and F2 rating Typical weatherable Valox resin grades
Custom color 364 Unfilled PBT+PC blend FR grade
Chemical resistance 3706 Unfilled PBT/PC FR blend, impact
modified and good weatherability,
High impact
passes V0 at 1.50 mm
Low warpage 357U, 357XU Unfilled PBT/PC impact modified FR
grade, passes V0 at 0.63 mm with an
Potential processing benefits: enhanced UV stability
Ultrasonic welding 3607U Enhanced UV-stabilized, FR, injection
molding grade, offering excellent
Good flow for large parts weatherability
Laser marking 553U 30% glass filled PBT/PC blend with
an excellent dimensional and UV
Product compliance: stability, passes UL 94 V0-0.86 mm
UL 746C 8032U 30% glass filled PBT/PET blend with
an excellent surface finish and
UL 94 weatherability
8032UX 30% glass filled PBT/PET blend has
Potential applications: excellent surface finish and improved
Outdoor cabinets weatherability v/s 8032U
815UX 15% glass filled PBT/PET blend with
Network interface devices
improved surface appearance and UV
Outdoor application where F1 rating is specified stability
830U 30% glass filled PBT/PET blend with
improved surface appearance and UV
stability
V3900WX Unfilled PBT/PC FR grade, passes
UL 94 at 1.5 mm. UV-stabilized F1
rated grade, passes UL 746C ( F1 )
weatherability performance
VX4920 20% glass filled nucleated PBT/ASA
blend with excellent mechanical
properties, dimensional stability and
weatherability
VX4930 30% glass filled nucleated PBT/ASA
blend with excellent mechanical
properties, dimensional stability and
weatherability
VX8015U 15% glass filled PBT/PET blend with
improved surface appearance and
excellent UV stability

Valox PBT/PET/PC resin GE Plastics 16

9. FDA (food contact) and healthcare
Valox resin
These Valox resin grades are excellent candidates to meet the
stringent requirements in healthcare due to their chemical resistance,
high heat resistance, gas and moisture barrier capabilities and ability
to withstand sterilization by gamma and e-beams radiation.

Potential application benefits: Potential applications:

Barrier capabilities and chemical resistance Food contact and cosmetic packaging
High heat resistance Medical and dental instrument
Low water absorption Housing and handles
Food contact Clamps and valves
Surface finish/gloss Complex injection molded shoulder inserts for
toothpaste tubes
Potential processing benefits: Co-extruded lids for yogurt pots
High flow, easy processibility
Recyclability Table 9
Surface finish, no secondary processing Typical FDA/medical Valox resin grades
215HPR PBT resin with mold release complies
with FDA regulations/biocompatible
Product compliance:
260HPR Unfilled PBT grade with mold release
Comply with FDA food contact regulations and compliant with food contact
regulations according to 90/128/EEC
312C Unfilled PBT with mold release and
food contact compliant
420HP 30% glass filled, excellent strength,
stiffness and dimensional stability,
FDA and biocompatible

17 GE Plastics Valox PBT/PET/PC resin

10. Specialty Valox resin
Valox resin specialty grades include structural foam for large parts and
weight reduction, as well as PBT lonomers to be used as additives for
other engineering plastics.
Structural foam PBT ionomers
Potential application benefits: Carpet fiber additive (Valox V2205 resin) application
Low stress for improved structural performance benefits:
Improved chemical resistance due to reduced stress Improved stain resistance for pre-colored PA 6/6
Excellent dimensional stability carpet fibers

Potential applications: Potential applications:

Air conditioning drain pans Carpet fiber additive
Electrical/mechanical/telecommunication housings
Support brackets Table 10.2
Typical PBT ionomers Valox resin grades
Call box
V2205 PBT ionomer

Table 10.1
Typical structural foam Valox resin grades
FV620 30% glass filled FR V-0, foam grade
FV650 30% glass filled non-FR
Blowing agent is Valox FVC 60/65

Valox PBT/PET/PC resin GE Plastics 18

11. Laser marking on Valox resin
GE has developed laser marking capabilities, offering a wide range
of Valox resin grades. In todays mass production environment, laser
marking is an easy, quick, permanent and economical option for
printing on your end product.
Laser
LASER is an acronym for Light Amplification by
Stimulated Emission of Radiation. Laser can be used
for various applications and technologies.
Benefits
Bar codes, safety information and all other
combinations of numerical, alphabetic and graphic
forms are regularly produced on a variety of
applications for marking. The help of lasers contributes
significantly to reduce production and part cost.
Typical benefits in using laser marking are:
Durability of the image
Flexibility because of use of fully automated digital
computer systems
No surface contact allowing complex geometries
and irregular surfaces
Speed allowing up to 2000 mm/sec or 200
characters/sec
Cleanliness and better for the environment as no
solvents or inks are applied
Laser systems
A given laser provides very high local energy input onto
the surface of the material to be marked resulting in
local degradation or chemical reaction, which in its
turn causes color changes.
The laser systems use the technique of engraving
or the technique of using a mask with the specified
image. The latter is not used that widely because of
less flexibility.
Three different kinds of systems are presently available
and applied on the market:
TEA-CO2 laser: Long wavelength of 10.600 nm
resulting in reduced resolution, it is the least
expensive and is mainly used with the mask
technology
Nd-YAG laser: Available in long wavelength of 1064
nm and/or short wavelength of 532 nm, offering
much higher image resolution then the CO2 lasers.
The YAG laser is the most commonly used laser for
laser marking and is in the mid- price range
Excimer lasers (UV): Available in very short
wavelengths of 193 ~ 351nm and therefore offering
the highest available image resolution at the highest
price range.
Laser settings
The polymer used, the application, and applied
equipment and settings determine the optimum laser
marking effect. The main variables on the equipment
are writing speed and consumed power/ amperage.
GE Plastics offers technical assistance to assess the
optimum settings and material support to strive
for the the highest required image resolution at the
highest writing speed and lowest amperage. For
more guidance please contact your local GE Plastics
representative.
19 GE Plastics Valox PBT/PET/PC resin
11. Laser marking on Valox resin
Laser marking effects
Many thermoplastic materials can be laser marked, in
dark as well as light or bright colors. We usually refer
to these effects as:
Lighton-dark
Showing a light mark on a dark surface
Dark-onlight
Showing a dark image on a light surface
Coloroncolor
Showing a distinctive colored mark on
a colored surface
Various effects can be achieved when thermoplastic
parts are being laser marked with a laser system. The
main effects are:
Foaming: Resulting in a light-on-dark effect
Carbonization: Resulting in a dark-on-light effect
Bleaching: Resulting in a color-on-color effect and
lighter color
Ablation: Resulting in a night and day effect
Foaming
The plastic material is heated locally by the laser beam,
which forms gas pockets. As a result the material
starts to foam and leaves a foamed light mark. Very
high contrast can be obtained in particular on dark
or black surfaces. As the mark is partly on top of the
surface it generally leads to a somewhat reduced wear
resistance.
Carbonization
The high local heating by the laser beam causes very
local carbonization of the polymer matrix, leaving a
black/brownish dark mark on the surface. The effect
is best seen on light colored materials. Excessive local
heating/carbonization can affect the mechanical
properties of the matrix. Achieving optimum settings is
required.
Valox PBT/PET/PC resin GE Plastics 20
Bleaching
Bleaching of the polymer surface locally, by the laser
beam, induces a superficial color change. As the
surface is hardly damaged with no unwanted side
effects, this is the most desirable effect. Limited plastic/
pigment combinations can be bleached. In general the
contrast of the mark is lower than the other effects/
techniques available.
Ablation
During ablation various (paint) layers can be selectively
removed from the surface locally by the laser beam.
This leads to one or more colored markings on the
parts surface. In most cases the night and day effect
is generated this way. A transparent plastic is painted
dark and the paint is subsequently removed by the
laser beam in the desired design, so the marking can
be seen.
General influences on the effect
The selection of the applied polymer matrix in relation
to the application and the marking contributes the
most to the final effect. It is polymer specific as to
how well the beam energy is absorbed and dissipated
through the material, resulting in a significant laser
marking effect (see Table 11.1).
The influence of additives on the quality of the image:
Glass fibers minimal effect
Minerals minimal effect
Flame retardants significant effect
Stabilizers minimal effect
Carbon black significant effect
Pigments significant effect
Excellent results
To achieve excellent results, GE Plastics can offer the
following support and service:
Match color of customer request (www.colormatch.
com)
Select matrix pigment combination for optimal
contrast (contact your GE sales representative)
Test and evaluate color plaques on contrast, and
define optimum settings (contact your GE sales
representative)
Develop new materials with new effects and higher
efficiency (contact your GE sales representative)

Table 11.1 Key laser marking grades

Grade Color
Material Matrix Dark-on-Light Light-on-Dark
PBT 325ML-54058LM 325-BK2B050L
PBT-FR VX3603-44012LM
PBT-GF 4031-BK2108L
420
PBT-GF-FR 451E-GN5B021L 451E-GY1B125L
420SEO-8233 420SEO-GY1B126L
PBT-PC-GF 508-WH4B201L
PBT-PC-GF-FR 553-BL1962L 553-BK1C052L
PBT-PC-IM-GF-FR 467-GN5B021L 467-GY1B125L
PBT-ASA-GF VX4930-BK2125L
PBT-PET-GF 815-BK1C012L
PBT-PET-IM-GF-MF 771-1001 735-BK1066L
PET-GF 9215Z/V9235
PET-GF-FR EXVX1135/V9561

21 GE Plastics Valox PBT/PET/PC resin

12. Valox resin product tree
Electricals - Enclosures, electrical VX3603C
357
357X
IM-General - Bobbins, switches,
Flame Retardant enclosures
357M
357XP
365
3706
V3900WX
IM-Weatherable - Base station,
box housing, NID 357U
357XU
Unfilled 364

215HPR
FDA - Healthcare, food contact 260HPR
312C
Aesthetics - Automotive bezel FXV310SK
Specialty - Nylon carpet additive V2202
Valox DLV3000
resin Non-Flame Retardant Metallizable - Ceiling reflectors
DLV3100
Impact Modified - Power
distribution boxes and covers 337
HR326

Hydrostable - Connectors, HR326HV

fibers, FOBT
K3501
V3100HR
Aesthetics - Steam iron parts,
Flame Retardant microwave parts, lighting parts 855
815

Aesthetics - Handles, kick plates, CS815

15% Glass toaster cover, grill handle
CS8115U
Filled
VX8016
K4530
Non-Flame Retardant Hydrostable - Automotive
connectors VX8016
VX4015

Weatherable - Washing machine 815UX

and oven parts
VX8015U

Valox PBT/PET/PC resin GE Plastics 22

 Flame Retardant Electricals - Electrical components 4521B
20% Glass
Filled Non-Flame Retardant Weatherable - Automotive connectors VX4920
CS860
Aesthetics 865
VX8532
V8560
Electricals - Connectors, mirco
Flame Retardant switches, component housings V9561
553
V4860HR
Hydrostable - Connectors for UTH
K4660
FDA - Medical, bowls, plates 420HP
30% Glass 830
Filled
Aesthetics - Iron skirt, appliance 830R
housings, handles
V9260CS
830X
VX4930
Valox
resin Weatherable - Heat pump 8032U
Non-Flame Retardant housing, bracket
8032UX
830U
Impact Modified - Ignition coil VIC4320N
Hydrostable - Automotive
connectors, sensors, brake module K4560

Electricals - Enclosures and housings,

Flame Retardant ciruit protection, MCB/MCCB/ELCB 771

Metallizable - Automotive Bezel EH7020HF

Glass and
Mineral 7062
Filled 7062X

Aesthetics - Bath/kitchen counter,

7065
Non-Flame Retardant furniture, mirror bracket
7085
7322
V4280
732E
Electricals - Oven grills,
adaptor rings 735
745

23 GE Plastics Valox PBT/PET/PC resin

13. Valox resin product information
Grade MFG. Location Heat Impact Modulus
A = Americas ISO 306 ASTM D 648 ISO 180/1A ASTM D 256 ISO 178 ASTM D 790 Flexural
E = Europe Vicat B/ HDT in C, 0.45MPa Notched Izod in Notched Izod in Flexural in MPa
P = Pacic 50 in C (1.82MPa), 6.4mm kJ/m2 at 23C/-30C J/m at 23C/-30C in MPa
General Purpose (See page 6)
325 A 175 154 6/6 5 2300 2345
310SEO A 165 162 5/3 3 2600 2620
4022 E,P 210 7/6 6000
420 A 215 215 5/5 8 8500 7586
457 A 190 204 6/5 3 3500 3513
451E A 200 212 6/5 4 6500 5515
420SEO A 205 212 8/7 7 9500 7586
Impact Modied (See page 7)
337 A 98 8 870 1790
357 A, E, P 137 534 2060
357M A 137 534 2060
357X E 145 45 2000
357XM E 137 534 2060
357P P 137 534 2060
357XP E, P 145 45/10 2000
365 A, P 129 640 2240
PDR4926 P 198 7 5221
VIC4311 A, P 175 205 12 137 6180 6080
VIC4320N E 210 9 6000
VIC4350 P 13 8490
VX3608C E 130 50 1800
Hydrostable (See page 8)
HR326 A, E 180 148 5/4 53 2500 2410
HR326HV A 148 53 2410
HR426 A 218 90 6890
K3501 A 8 89 2020 2080
K4530 A 58 0 4640
K4560 A 96 6200
V3100HR A 148 53 2410
V4860HR A, E, P 176 10/8 90 7870 6740
VX4015 E 200 12/8 4200

Valox PBT/PET/PC resin GE Plastics 24

Flame Characteristics CTI RTI UL 746B Grade
UL 94 IEC UL 746A, Electric Mechanical Mechanical
Flammability 60112 PLC Code with Impact w/o impact
Rating @ Thickness (mm) Unit: V

HB @ 1.5 600 0 120 120 140 325

V0 @ 0.71 175 3 120 120 140 310SEO
HB @ 0.8 250 4022
HB @ 0.8 300 0 140 140 140 420
V0 @ 0.71 175 3 120 120 140 457
V0 @ 0.71 175 3 120 120 140 451E
V0 @ 0.71 175 3 130 130 140 420SEO

337
120 120 140 357
V0 @ 0.63 2 120 120 140 357M
V0 @ 0.8 225 120 120 140 357X
V0 @ 0.8 2 120 120 140 357XM
V0 @ 0.8 2 120 120 140 357P
V0 @ 0.8 225 120 120 140 357XP
105 105 105 365
V0 @ 0.75 PDR4926
VIC4311
VIC4320N
V0 @ 1.5 VIC4350
V2 @ 1.6 225 VX3608C

HB @ 1.6 600 0 HR326

HR326HV
V0 @ 0.76 1 140 140 140 HR426
K3501
K4530
K4560
V3100HR
V0 @ 0.8 V4860HR
300 VX4015

25 GE Plastics Valox PBT/PET/PC resin

13. Valox resin product information
Grade MFG. Location Heat Impact Modulus
A = Americas ISO 306 ASTM D 648 ISO 180/1A ASTM D 256 ISO 178 ASTM D 790 Flexural
E = Europe Vicat B/ HDT in C, 0.45MPa Notched Izod in Notched Izod in Flexural in MPa
P = Pacic 50 in C (1.82MPa), 6.4mm kJ/m2 at 23C/-30C J/m at 23C/-30C in MPa
Electrical (See page 10)
467 E, P 155 7/6 7600
771 A, E, P 180 217 5/5 42 8500 5860
4521 E, P 205 6 7400
4521B E 205 6/5 7400
553 A, E, P 170 204 7/7 8 8000 6899
732E A 215 101 6890
735 A, E, P 173 215 5/4 74 9000 8270
745 A, E, P 138 160 80 3400 3440
V8560 E 200 7 8000
V9561 E 225 7 10750
VX3603C E 180 4 2750
Aesthetics Color Stable (See page 11)
815 A, E, P 185 210 6/5 37 5200 4480
815F E 200 5000
830 A, E, P 200 221 9/8 80 9000 6890
830EI, 830M P 221 80 6890
830R P 192 80 6890
830X E 175 5/5 7000
855 A, E, P 190 204 6/6 53 5000 4820
865 A, E, P 200 212 7/6 80 8000 7580
CS8115 A 157 37 5000
CS8115U A, P 157 37 5000
CS815 A 48 5170
CS860 A, P 212 80 8270
V4280 A 215 10 10690
V9260CS E 9800
V9540CS E 8500
VX8016 E 4 4250
VX8532 E 200 9500
Aesthetics Heavy (See page 12)
7062, 7062HP A, E 175 3 3900
7065 A, E 193 2 5397
7085 E 204 8 3445
7322 A 160 8 2689
7062X E 200 5 7400
Aesthetics Visualfx (See page 14)
FXV310SK E 185 5 2750

Valox PBT/PET/PC resin GE Plastics 26

Flame Characteristics CTI RTI UL 746B Grade
UL 94 IEC UL 746A, Electric Mechanical Mechanical
Flammability 60112 PLC Code with Impact w/o impact
Rating @ Thickness (mm) Unit: V

V0 @ 1.5 130 120 140 467

V0 @ 0.8 600 0 140 125 140 771
V0 @ 0.8 275 130 130 130 4521
V0 @ 0.8 275 4521B
V0 @ 0.9 225 3 125 110 125 553
732E
HB @ 0.8 2 140 140 140 735
HB @ 1.5 105 105 105 745
V8560
V0 @ 0.8 200 V9561
V0 @ 0.75 275 VX3603C

HB @ 1.5 325 2 125 110 125 815

HB @ 1.6 325 2 815F
HB @ 1.5 325 2 120 120 830
2 120 120 830EI, 830M
120 120 830R
HB @ 1.5 830X
V0 @ 1.5 225 3 125 110 125 855
V0 @ 1.5 225 3 110 110 110 865
CS8115
CS8115U
CS815
V0 @ 0.76 3 130 130 140 CS860
V4280
V0 @ 0.8 V9260CS
175 V9540CS
200 VX8016
V0 @ 1.6 200 VX8532

HB @ 1.5 475 7062, 7062HP

HB @ 1.49 75 75 75 7065
HB @ 1.49 600 0 75 75 75 7085
HB @ 1.49 1 120 120 125 7322
HB @ 1.5 7062X

600 FXV310SK

27 GE Plastics Valox PBT/PET/PC resin

13. Valox resin product information
Grade MFG. Location Heat Impact Modulus
A = Americas ISO 306 ASTM D 648 ISO 180/1A ASTM D 256 ISO 178 ASTM D 790
E = Europe Vicat B/ HDT in C, 0.45MPa Notched Izod in Notched Izod in Flexural Flexural
P = Pacic 50 in C (1.82MPa), 6.4mm kJ/m2 at 23C/-30C J/m at 23C/-30C in MPa in MPa
Metalizable (See page 15)
DLV3000 P 25 2410
DLV3100 P 25 2330
EH7020HF A, E, P 70 27 4710
Weatherable (See page 16)
364 A 747 1860
3706 A 1990
357U A, P 137 534 2060
357XU E 145 45/10 2000
3607U E 125 50/20 2050
553U 204 8 6899
8032U E 202 9/8 8500
8032UX E 202 9 8500
815UX E 200 6/5 4700
830U P 220 88
V3900WX A, P 121 41 800 2130 2200
VX4920 E 158 6 6000
VX4930 E 176 7 8500
VX8015U E 200 6/5 5000
FDA/Medical (See page 17)
215HPR A 154 53 2340
260HPR E 175 5 2300
312C E 175 3 2400
420HP A 215 85 7580
Specialty (See page 18)
FV620 A, P 201 7655
FV650 A, P 209 9 7684
V2205 A

Valox PBT/PET/PC resin GE Plastics 28

Flame Characteristics CTI RTI UL 746B Grade
UL 94 IEC UL 746A, Electric Mechanical Mechanical
Flammability 60112 PLC Code with Impact w/o impact
Rating @ Thickness (mm) Unit: V

DLV3000
DLV3100
EH7020HF

75 75 75 364
V0 @ 1.49 100 85 100 3706
V0 @ 0.63 2 120 120 140 357U
V0 @ 0.8 225 120 120 140 357XU
V1 @ 3.0 225 80 80 80 3607U
V0 @ 0.86 3 125 110 125 553U
HB @ 1.6 8032U
8032UX
HB @ 1.5 300 815UX
830U
5VA @ 3.0 75 75 75 V3900WX
HB @ 1.6 450 VX4920
HB @ 0.8 500 VX4930
HB @ 1.6 325 VX8015U

215HPR
HB @ 1.5 600 0 75 75 260HPR
HB @ 1.5 600 0 312C
420HP

V0 @ 3.91 3 75 75 75 FV620
FV650
V2205

29 GE Plastics Valox PBT/PET/PC resin

14. Mold design
Mold Materials Casting Process
Steel selection in tooling for Valox resin can be as Kirksite - a metal casting material
critical to the performance of an application as Aluminum
the selection of the resin for the molded product. Plastics, epoxies
Just as resin are formulated to meet performance Liquid Plating Process
requirements in plastics applications, steels are Intricate shells can be nickel-plated on a master.
alloyed to meet specific performance requirements in These are later backed up and inserted into a mold
use. frame.
Some applications may require a mold steel with Flame Spraying
high hardness and wear resistance for parting line Flame spray metals can quickly produce a 1/8 inch
durability, while others will require a mold steel with (3.16 mm) thick shell which is further backed up
higher toughness for resistance to mechanical fatigue. and placed into a regular frame. A variety of metals
In general, steels delivering higher hardness and wear which come in wire form can be utilized into the
resistance properties are those that tend to be more process.
brittle, and in almost all cases, a steel with greater
toughness will deliver some reduction in resistance Sprues and Runners
to steel-to-steel wear (adhesive wear) and abrasive It is suggested that a cold-slug well be provided at
resistance to resin containing glass fibers or mineral the base of the sprue to receive the cold material
fillers. first emerging from the nozzle. Well diameter should
typically be equal to the largest diameter of the sprue,
Prototype Tooling with depth 1-1/2 times this diameter. Wells should
Soft, lower-cost molds serve a valuable function also be furnished in the runner system by extending
by providing preproduction parts for marketing the runner at least 1-1/2 times the runner diameter
studies, manufacturing assembly requirements and beyond every 90 turn. See Figure 14.1 below.
dimensional capabilities, and by giving the designer an
Figure 14.1 Sprue Design
opportunity to evaluate some unusual function.
All casting and plating processes require a model
which will be faithfully reproduced. The quality and Sprue O Dimension
0.175 (4.5 mm)
durability of prototype tooling depends on the process. Machine Nozzle Location Ring
Some molds may produce fewer than 100 pieces,
whereas others may function for many thousands of
pieces. The cost and timing of the project may be the
deciding factor in which method is used.
Some important molding information can also be
gained which can be later translated to the production
Sprue Bushing
mold. Some common forms of producing prototype Fixed Half
molds are as follows:
2-6
Conventional Machining Materials
Moving Half
Steel (unhardened)
Aluminum
Cold Slug Sprue Puller
Brass
Ejector Pin
Trademark of NL Industries

Valox PBT/PET/PC resin GE Plastics 30

Cold Sprues
Figure 14.3 Profile: Valox 508 and 553 resin
A standard sprue bushing of 1/2 or 3/4 inch (12.7 or
19.05 mm) taper per foot should have a minimum grades mold shrinkage vs. wall thickness
O dimension of 7/32 inch (5.56 mm) diameter. The
diameter of the sprue at the parting line should be
equal to, or slightly larger than, the runner diameter.
An oversized sprue diameter at the runner intersection

Mold Shrinkage, mils/in

may result in a longer molding cycle. The sprue bushing
should have a 1/32 to 1/16 inch (0.79 to 1.59 mm)
Cross
radius at the runner intersection. A reverse-tapered or Flow
dovetailed cold well can act as a sprue puller at the
runner intersection.
Flow
Shrinkage vs. Wall Thickness
The wall thickness of a part is the most significant
variable affecting mold shrinkage. Thicker wall sections
shrink more than thinner parts. Figures 14.2 through Wall Thickness, in
14.9 depict the effects of wall thickness on mold
shrinkage of five Valox resin families.
These curves represent shrinkage that can be expected Figure 14.4 Profile: Valox glass-filled resin
when processing Valox engineering thermoplastics mold shrinkage vs. wall thickness
resin at the standard conditions suggested. Part
geometry and varying processing conditions can affect Flow Direction
shrinkage. Prototype tests in part geometry will provide
the most reliable data for a particular application.
Mold Shrinkage, mils/in

Additional information on shrinkage can be obtained

from GE Plastics Technical Services in Pittsfield, MA, at
(800) 845-0600.
Valox DR 51 resin

Valox DR 48, 420 resin

Figure 14.2 Profile: Valox 300 resin grades mold

shrinkage vs. wall thickness
Valox 414, 420 SEO resin

Flow and Cross-Flow Direction

Wall Thickness, in
Valox 325 resin
Mold Shrinkage, mils/in

Valox 315 resin

Valox 357 resin

Wall Thickness, in
Nominal values normally 0.002" due to variance in processing.
31 GE Plastics Valox PBT/PET/PC resin
14. Mold design
Figure 14.5 Profile: Valox glass-filled resin Figure 14.8 Profile: Valox 800 resin grades
mold shrinkage vs. wall thickness mold shrinkage vs. wall thickness

Cross-Flow Direction Flow Direction

Mold Shrinkage, mils/in

Mold Shrinkage, mils/in

Valox 420, 420 SEO resin

Valox 815, 850, 855 resin
Valox DR 51, DR 48 resin

Valox 414 resin

Valox 830 resin

Wall Thickness, in Wall Thickness, in

Figure 14.6 Profile: Valox 700 resin grades Figure 14.9 Profile: Valox 800 resin grades
mold shrinkage vs. wall thickness mold shrinkage vs. wall thickness

Flow Direction Cross-Flow Direction

Valox 744 resin
Mold Shrinkage, mils/in

Mold Shrinkage, mils/in

Valox 745 resin

Valox 815, 850, 855 resin

Valox 701 resin

Valox 751, 735 resin

Valox 830 resin

Valox 780 resin

Wall Thickness, in Wall Thickness, in

Figure 14.7 Profile: Valox 700 resin grades
mold shrinkage vs. wall thickness
Cross-Flow Direction
Valox 745 resin
Mold Shrinkage, mils/in

Valox 745 resin

Valox 701, 751 resin

Valox 735, 780 resin

Nominal values normally 0.002" due to variance in processing.

Wall Thickness, in

Valox PBT/PET/PC resin GE Plastics 32

15. Equipment
Machine Selection
When determining the size of equipment to be used
for molding a particular Valox resin part, total shot
weight and total projected area are the two basic
factors to be considered.
Optimum results are generally obtained when the
total shot weight (all cavities plus runners and sprues)
is equal to 30 to 80% of the machine capacity. Very
small shots in a large barrel machine may create
unnecessarily long resin residence times which may
lead to resin degradation.
If it is necessary to mold at the high end of the
temperature range, reduced residence time is usually
required to reduce the possibility of material heat
degradation. Therefore, for higher temperature
molding requirements, it is suggested that the
minimum shot size be greater than 60% of the
machine capacity.
Once the total projected area of the complete shot
(all cavity and runner areas subjected to injection
pressure) has been determined, 3 to 5 tons of clamp
force should be provided for each square inch of
projected area to reduce flashing. See Figure 15.1
below.

Figure 15.1 Clamping force for Valox resin

Projected Area, 103 mm2
Clamping Force, tons

Clamping Force, N

3-6 Tons per sq. inch for

Glass Reinforced Resin
3-5 Tons per sq. inch
for for Unfilled Resin

Projected Area, inches2

33 GE Plastics Valox PBT/PET/PC resin

15. Equipment
Drying Parameters
Valox resin will absorb a small amount of water
from the atmosphere after compounding and prior
to processing. The amount absorbed will depend on
environmental conditions, and may vary from 0.10 to
0.25%, depending on the temperature and humidity of
the storage area.
In order to enhance performance of molded parts and
to reduce the possibility of degradation, all grades of
Valox resin must be dried before processing. Resin
should be dried until the moisture level is less than
0.02%, typically 3 to 4 hours at 250F (121C) (other
drying parameters may apply to specialty resin).
When using oven dryers, the resin should be spread in
trays to a depth of approximately 1 inch (25.3 mm). For
large pellet size (regrind) or glass filled materials, the
residence time should be increased to 4 to 6 hours.
Figure 15.2 shows a typical drying curve for Valox
resin compounds. To avoid excessive heat history, it is
suggested that the material be dried no longer than
48 hours.
The hopper and any open areas of the feed
mechanism should be covered to protect the dried
pellets from room atmosphere. If a hopper dryer
is not available, only a sufficient quantity of dried,
heated Valox pellets should be removed from the oven
and placed in the hopper at one time. The length of
exposure to ambient atmosphere which the dried resin
can withstand before a potentially harmful amount of
moisture is absorbed can range from 15 minutes to
several hours depending on relative humidity.
Valox PBT/PET/PC resin GE Plastics 34
Where hopper dryers are available, oven drying can
also be helpful to dry a quantity of resin for start-
up. After start-up, a hopper of sufficient volume to
maintain the resin for a 3 to 4 hours minimum at
250F (121C) is required. The hopper dryer should be
preheated to the suggested drying temperature before
the pellets are loaded in. Air entering the hopper
should be at 250F (121C) and have a flow of 1.0 CFM
for every pound per hour of use.
Drying Specialty Resin
Other drying parameters may apply to more recently
developed Valox resin grades, either in their virgin
state or as regrind.
Prior to running new Valox resin, refer to data sheets
or contact a GE representative to confirm that
suggested processing procedures are known. Call
Product Support at (800) 845-0600 to request product
literature or for technical information.
Figure 15.2 Representative drying curves for
standard Valox resin grades
Pellets in trays; 1 inch deep, dried at 250F
Entrance
Moisture
% Moisture
Content: Suggested
Low High Maximum
Moisture
Level
Hours of Drying
16. Molding conditions
Control over processing conditions is critical to the economical
production of quality parts. Fast cycles and low reject rates are
both important in successful processing.
For typical processing parameters of Valox resin compounds,
see Table 16.1.
Melt Temperature
Like the majority of thermoplastic molding materials,
Valox resin are sensitive to prolonged exposure
to heat. Long residence times and excessive melt
temperatures should be avoided. A relatively
small increase in screw speed (RPM) can result in
a dramatic increase in melt temperature with no
change in controller set point. It is suggested that
melt temperatures be measured using hand-held
pyrometers. These measures should be taken on the
thermoplastic melts after the machine is on cycle.
A useful guide to time/temperature relationships is
shown in the area molding diagram (Figure 16.1).
In general, serious loss of properties or gas build-
up is expected to occur when operating within the
limits indicated. Valox resin, like other engineered
thermoplastics, should not be left at elevated
temperatures for prolonged periods of time without
occasional purging.
Figure 16.1 Residence time/temperature area
molding diagram
Temperature C
Mineral, Mineral/Glass,
Glass-Reinforced Valox Resin
Time, Minutes
Unfilled Valox Resin
Flame Retardant
Valox Resin
Temperature F
Mold Temperature
Valox resins rapid crystallization rate and other
crystalline characteristics allow a wide range of mold
temperatures without significant effects on physical
properties.
The usual range for processing unreinforced Valox
grades is from 120 to 180F (38 to 60C); higher
temperatures will typically give the surface a very
smooth, glossy appearance. The aesthetic appeal
of surfaces molded in reinforced Valox resin can be
enhanced by the use of fast fill rates, higher injection
pressures and mold temperatures in the 150 to
225F (66 to 107C) range. Operating molds in this
temperature range can also be used to improve flow,
knitline strength and surface finish in reinforced resin.
When using reinforced Valox resin, mold temperatures
higher than 150F (66C) and the maximum
permissible ram speed are suggested to help
achieve a high-gloss surface. All component parts
of an assembly should be molded at the same mold
temperature to assure color consistency when
molding at temperatures over 150F (66C) (see Table
16.1).
35 GE Plastics Valox PBT/PET/PC resin
16. Molding conditions
Typical Processing Parameters
Table 16.1 Typical injection molding processing parameters for Valox resin.
730
815 732E
830 735
325 420 855 736
325ML 357 420SEO 865 745
HR326
310 327 364 508 DR48 771
310SEO 337 365 553 DR51 780 HR426
Processing Parameters Units (min.) (max.) (min.) (max.) (min.) (max.) (min.) (max.) (min.) (max.)
Drying Temperature F(C) 250(121) 250(121) 250(121) 250(121) 140(60) 170(77)
Drying Time (Normal) h 3 4 3 4 3 4 3 4 4 5
Drying Time (Max.) h 12 12 12 12 8
Maximum Moisture % 0.02 0.02 0.02 0.02 0.05
Melt Temperature F(C) 470(243) 500(260) 480(249) 510(266) 480(249) 510(266) 490(254) 530(277) 480(249) 510(266)
Nozzle F(C) 460(238) 490(254) 470(243) 500(260) 470(243) 500(260) 490(254) 520(271) 470(243) 500(260)
Front Zone F(C) 470(243) 500(260) 480(249) 510(266) 480(249) 510(266) 490(254) 510(266) 480(249) 510(266)
Middle Zone F(C) 460(238) 490(254) 470(243) 500(260) 470(243) 500(260) 480(249) 500(260) 470(243) 500(260)
Rear Zone F(C) 450(232) 480(249) 460(238) 490(254) 460(238) 490(254) 470(243) 490(254) 460(238) 490(254)
Mold Temperature F(C) 120(49) 170(77) 120(49) 170(77) 150(66) 190(88) 150(66) 200(93) 150(66) 190(88)
Back Pressure psi(MPa) 50(0.3) 100(0.7) 50(0.3) 100(0.7) 50(0.3) 100(0.7) 50(0.3) 100(0.7) 50(0.3) 100(0.7)
Screw Speed rpm 50 100 50 100 50 80 50 80 50 80
Shot to Cylinder Size % 40 80 40 80 40 80 40 80 40 80
Clamp Tonnage tons/in2 3 5 3 5 3 6 3 6 3 6
Vent Depth in 0.0005 0.0010 0.0005 0.0015 0.0005 0.0015 0.0005 0.0015 0.0005 0.0015

Valox PBT/PET/PC resin GE Plastics 36

Screw Speed
Screw speeds (RPM) should be adjusted to permit
screw rotation during the entire cooling cycle without
delaying the overall cycle (Figure 16.2). Low screw
speeds will help reduce glass fiber damage during
plastication when molding reinforced grades.
Suggested screw speed is dependent on screw
diameter. Optimum linear velocity of screw O.D. is 8
inches (202.4 mm) per second. RPM = screw diameter
divided into the optimum linear velocity of 8 inches
(202.4 mm) per second 60. For example, for a 3 inch
(76.2 mm) diameter screw: 3 (screw Dia.) 3.1416 =
9.4248 divided into 8 inches (202.4 mm) per second
(optimum linear velocity) 60 = 51 RPM.
Back Pressure
A back pressure of 50 to 100 psi (0.17 to 0.34
MPa) is suggested to ensure a homogeneous melt
and consistent shot size. Higher back pressures
used to improve melt mixing result in higher melt
temperatures.
When molding reinforced grades, low back
pressure will help reduce glass fiber damage during
plastication.
Figure 16.2 Screw speed suggestions for
Valox resin
RPM
MAXIMUM
OPTIMUM
MINIMUM
Screw Diameter, in
Shot Size
The suggested shot size is 30 to 80% of the machine
capacity. For blended grades where color control is
critical, it is suggested the shot size be as close to 60%
of machine capacity as possible in order to reduce
residence times.
Ram Speed
When selecting injection speed, careful consideration
must be given to adequate mold venting, resin melt
temperature and injection pressure, along with the
potential for jetting.
The fastest fill speed possible generally provides
longer flow, fills thinner wall sections and creates
better surface finish. In thick parts, slow fill helps
reduce voids. Valox resin require a fast fill to help
prevent premature freeze-off. Thin-wall sections below
0.06 inch (1.52 mm) require fast ram speeds in order
to fill the cavity and enhance knitline strength. The fill
rate of thick sections may be reduced to aid packing
when filling through restricted gates.
Programmed injection is suggested for parts with
small gates (pin gates and subgates). A slow injection
rate can be used at the start to reduce shear, jetting
and burning of the material.
Injection Pressure
The actual injection pressure will depend on variables
such as melt temperature, mold temperature, part
geometry, wall thickness, flow length and other mold
and equipment considerations. Generally, the lowest
pressures which provide the desired properties,
appearance and molding cycle are preferred.
Valox resin flow relatively easily, however, medium to
high injection pressure may be required to fill intricate
part configurations or thin walls. Normal injection
pressures are 8,000 to 10,000 psi (55 to 69 MPa) for
unreinforced grades or 10,000 to 18,000 psi (69 to 124
MPa) for reinforced or filled grades.
37 GE Plastics Valox PBT/PET/PC resin
16. Molding conditions
Holding pressures from 60 to 80% of the injection
pressure are usually adequate for normal
requirements.
Due to the speed at which Valox resin crystallizes,
thin-walled parts with small gates may require only
moderate holding pressure. However, thick sections
with large gates will typically require high holding
pressures and longer holding times.
Cushion
The use of a small cushion (1/8 inch [3.18 mm]
suggested) reduces material residence time in the
barrel and helps accommodate machine variations.
Cycle Time
Cycle time is primarily dependent on part thickness,
therefore thin sections from 0.03 inch to 0.06 inch (0.76
to 1.52 mm) usually give overall cycles of about 10 to
18 seconds, while thicker sections of up to 0.15 inch
(3.81 mm) can usually be molded in about 40 seconds.
Specific cycle time is dictated by part and mold design.
The fastest possible ram travel time is best for most
parts. The thickest wall section of the part normally
sets the cycle time. Figure 16.3 illustrates the overall
cycle time prediction as a function of wall thickness.
A runner/sprue section could exceed the part wall
Effect of Wall Thickness on Flow Length
Valox resin flow relatively easily because of the low
melt viscosity of PBT; however, the fast crystallization
of PBT resin limits flow capability. Variables affecting
mold flow length include wall thickness, mold
temperature, injection pressure, melt temperature and
material composition. For example Valox resin flow
longer in thicker sections versus thin sections. And,
unreinforced resin usually flow farther than glass-
reinforced resin at similar pressure.
Figures 16.4 through 16.8 show flow properties of
different Valox resin as a function of wall thickness.
It should be emphasized that increasing melt
temperature has minimal effect on flow length. In
general, melt temperatures should be kept below
510F (266C) to prevent thermal degradation.
Figure 16.4 Flow length vs. wall thickness Valox
300 resin grades
Wall Thickness, mm
Melt Temp. 500F (260C) Valox 325 resin
Mold Temp.150F (66C)
Inj. Press: 15,000 psi (103 MPa)
Flow Length, in.

Flow Length, cm
thickness and extend cycle times shown in Figure 16.3.
This should be a consideration before the tool is built, Valox 310SEO resin

as well as during actual molding.

Valox 327 resin

Figure 16.3 Typical cycle time vs. wall thickness for

Valox resin Wall Thickness, in.
Wall Thickness, (mm)
Figure 16.5 Flow length vs. wall thickness Valox
400 resin grades
Wall Thickness, mm
Cycle Time (seconds)

Melt Temp. 500F (260C)

Mold Temp.180F (82C)
Flow Length, cm

Inj. Press: 15,000 psi (103 MPa)

Flow Length, in.

Valox DR-48 resin

Valox 420SEO resin

Valox 420 resin

Wall Thickness, in Wall Thickness, in.

Valox PBT/PET/PC resin GE Plastics 38

Figure 16.6 Flow length vs. wall thickness Valox
700 resin grades

Figure 16.7 Flow length vs. wall thickness Valox

800 resin grades

Figure 16.8 Thin wall flow of Valox resin

39 GE Plastics Valox PBT/PET/PC resin

Americas Headquarters:
GE Plastics
One Plastics Avenue
Pittsfield, MA 01201
USA
T: 1 413 448 7110
F: 1 413 448 5573

European Headquarters:
GE Plastics
Plasticslaan 1
PO Box 117
NL - 4600 AC Bergen op Zoom
The Netherlands
T: +31 164 292911
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200040 Shanghai
China
T: +86 21 3222 4500
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E-mail: gelit@ge.com
geplastics.com

Disclaimer : THE MATERIALS AND PRODUCTS OF THE BUSINESSES MAKING UP THE GE PLASTICS UNIT OF GENERAL ELECTRIC COMPANY, ITS
SUBSIDIARIES AND AFFILIATES (GEP), ARE SOLD SUBJECT TO GEP S STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE
DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON
REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GEP MAKES NO
WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (I) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS,
OR (II) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING GEP MATERIALS, PRODUCTS, RECOMMENDATIONS OR ADVICE.
EXCEPT AS PROVIDED IN GEP S STANDARD CONDITIONS OF SALE, GEP AND ITS REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR
ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS OR PRODUCTS DESCRIBED HEREIN. Each user bears full responsibility for making
its own determination as to the suitability of GEP s materials, products, recommendations, or advice for its own particular use. Each user
must identify and perform all tests and analyses necessary to assure that its finished parts incorporating GEP materials or products will be
safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be
deemed to alter, vary, supersede, or waive any provision of GEP s Standard Conditions of Sale or this Disclaimer, unless any such modification
is specifically agreed to in a writing signed by GEP. No statement contained herein concerning a possible or suggested use of any material,
product or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of General
Electric Company or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material,
product or design in the infringement of any patent or other intellectual property right
* Valox, Visualfx, Enduran and Lexan are trademarks of General Electric Company.
2006 General Electric Company. All Rights Reserved.

PLA-2734-REV2-0806